Case Study · Alcohol & Ethanol
Ethanol Production Control System Retrofit and Upgrade
Obsolete control system retrofit and upgrade, with plant expansion preparation.
Project Summary
Opened in 2001, Golden Triangle Energy Cooperative (GTEC) produces about 20 million gallons of ethanol each year. In 2007, GTEC contracted long-time partner Bachelor Controls to retrofit its obsolete control system with a newer, more flexible system that could meet future production and product expansion needs.
Challenge
GTEC charged BCI with retrofitting and replacing an obsolete control system with a newer, more flexible one operating under the following parameters:
- Retain all field wiring and field devices
- Maintain existing control functionality operating on newer, more current hardware
- Allow flexibility for day-to-day operational modifications and planned facility and product expansion needs
- Ensure parts and technical support, including training, are readily available
- Implement a system that has a pool of skilled talent readily available to maintain and support it
We knew the magnitude of the controls conversion project would be like a 'heart transplant' for our facility. We take great comfort in knowing our control system is designed to meet our specific needs, with replacement parts available locally. We relied on Bachelor Controls to guide us in making the most effective decisions for our control system needs. I don't see how we could have done this project any other way.
Solution & Benefits
BCI retrofitted and replaced the existing control system in two phases. A pilot phase tested the implementation plan and device-control software modules under load. The major implementation phase was then installed in only five days, during a scheduled plant shut-down.
Results
5 days
Major installation window
2
Implementation phases
100%
Field wiring and devices retained
20M
Gallons of ethanol per year
What GTEC Kept, and What Changed
- Provided current technology and hardware
- Reduced installation costs by leveraging all existing field wiring and field devices
- Maintained control functionality, plus built-in flexibility for future facility and product expansions
- Installed parts that are readily available from reliable distributors located near GTEC
- Featured an open architecture with increased availability of training and maintenance support resources
- Minimized down-time costs by containing the major installation phase to only five days during a scheduled shut-down
- Improved efficiency of system control operations, so GTEC can focus on production and processing issues
Inside the Project
What the Customer Said
Bachelor Controls' planning and preparation for the ethanol production control system conversion project was excellent. They clearly understood the tremendous amount of detail that was going be required implementing the new system during a single, scheduled shut-down. When it came time to execute, they were poised and ready to go.
Running Obsolete Controls?
Tell us what has to stay in place, and how long a shut-down you can afford.